REACTOR OPERATION
1. REACTOR
Types of reactor :ssr,glr,hastolly reactor
Types of condensers :sheel and tube
Types of jackets:shell and limpet type
Moc: ss316,ss316 contains 16-18%chromium and 11-14% nickel
and remaining iron. ss reactor suitable for pH 7.0 to 14 and glr suitable for
pH 1.0 to 7.0
Types of agitators:anchor,propeller,turbine
Baffles:paddle type baffles,using onside and two opposite
sides in reactor
Reactor capacity and part : as per batch size and urs 1.motor 2.gear box 3.agitator 4.bottom value
5.jacket 6.temperature sensor 7.safety value 8.nitrogen line 9.manhole or hand
hole 10.flame arrester 11. reflux line
Guages:
1.pressure guage: Measured the unit of forcesurface
area.pressure is measured in kg/cm2 or lb/cm2
2.vacuum guage :A vacuum is a space in which the pressure of
a gas is low compared to the atmospheric pressure. The measure of vacuum is
associated with pressure. Vacuum gauges and instruments are used in conjunction
with vacuum sensors to monitor and control the vacuum pressure in a system.
3.compound guage: A compound gauge is a device that can
display both positive and negative (vacuum) pressures (vacuum and pressure
gauge). You need to use a compound Pressure Gauge when you are measuring a
system that is exerting both positive and negative pressure on the gauge.
Agitator :Agitation refers to forcing a fluid by mechanical
means to flow in circulatory or other pattern inside a vessel.mixing of two or
more separate phases,such as a fluid and a powdered solid or two fluids and
causing them to be randomly distributed through one another.
- agitation leads to collision of reactants.
- agitator speed can be varied by varying the RPM motor.
- depends on the process requirement reaction/precipitation/crystallization/extraction/distillation rpm varies
Utilities:
The following utilities is being used in the jacket of reactor.
1.steam/hot water/ct water
2.brine (-10,-25,)
3.Nitrogen/air
4.liquid nitrogen(-194 C)
Descaling of reactor jacket:
1. ssr :10%sulfonic acid solution at 70-80C
2. glr: 3-4% sodium hypo chlorite solution
Type of insulation to the jacket:
1.Hot insulation:Jacket insulated with glass wool.suitable for hot (steam) application.
2.cold insulation:jacket insulated with poly urethane foam (puf). suitable for cold (ct water /-10/-40/-70) applications.
3.Dual insulation: jacket insulated with the layers of glass wool and puf. suitable for hot and cold application.
Precaution with insulation:
1.acidic contents should not fall between the insulation and reactor jacket .
2.if fallen, corrosion occurs resulting reactor jacket damage.
purpose of insulation:
1.insulation is used in manufacturing processes to prevent heat loss or heat gain from atmosphere.
2.although its primary purpose is an economic one its also provides more accurate control of process temperature.
3.its prevents corrosion on cold surfaces and resulting corrosion.
safety value :
1.reactor safety value set pressure 3.0kg /cm2 (this set pressure can be changed depend on the requirement.
Type of insulation to the jacket:
1.Hot insulation:Jacket insulated with glass wool.suitable for hot (steam) application.
2.cold insulation:jacket insulated with poly urethane foam (puf). suitable for cold (ct water /-10/-40/-70) applications.
3.Dual insulation: jacket insulated with the layers of glass wool and puf. suitable for hot and cold application.
Precaution with insulation:
1.acidic contents should not fall between the insulation and reactor jacket .
2.if fallen, corrosion occurs resulting reactor jacket damage.
purpose of insulation:
1.insulation is used in manufacturing processes to prevent heat loss or heat gain from atmosphere.
2.although its primary purpose is an economic one its also provides more accurate control of process temperature.
3.its prevents corrosion on cold surfaces and resulting corrosion.
safety value :
1.reactor safety value set pressure 3.0kg /cm2 (this set pressure can be changed depend on the requirement.
2.jacket safety value set pressure 5kg/cm2
3.safety value fixed at the jacket out let of the reactor and top of the reactor .if pressure is crossed more than the set pressure automatically safety relief value will open and release excess pressure than the set point.
Agitator sealing:
1.To avoid leakages of vapour from the reactor to atmosphere or to avoid atmospheric air entry into the reactor.
types of sealing
1.gland packing
2.single dry mechanical seal
3.double mechanical seal
calibration reactor instruments:
1.pressure/vacuum/compound guage
2.temperature indicator.
3.level indicator or level transmitter
preventive maintenance for reactor:
1.reactor monthly,quaterly,half yearly,yearly preventive maintenance.
2.gear box
3.jacket safety value
4.earthing continutity checking
5.motor
6.flame arrester
3.safety value fixed at the jacket out let of the reactor and top of the reactor .if pressure is crossed more than the set pressure automatically safety relief value will open and release excess pressure than the set point.
Agitator sealing:
1.To avoid leakages of vapour from the reactor to atmosphere or to avoid atmospheric air entry into the reactor.
types of sealing
1.gland packing
2.single dry mechanical seal
3.double mechanical seal
calibration reactor instruments:
1.pressure/vacuum/compound guage
2.temperature indicator.
3.level indicator or level transmitter
preventive maintenance for reactor:
1.reactor monthly,quaterly,half yearly,yearly preventive maintenance.
2.gear box
3.jacket safety value
4.earthing continutity checking
5.motor
6.flame arrester
7.rupture disc
sop related to reactor:
1.operation of reactor
2.cleaning of reactor
3.charging of solids
4.charging of liquids
5.sampling from reactor
6.loading and unloading of utilities
7.descaling of reactor
sop related to reactor:
1.operation of reactor
2.cleaning of reactor
3.charging of solids
4.charging of liquids
5.sampling from reactor
6.loading and unloading of utilities
7.descaling of reactor
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